304 replies to this topic

[Ben_O]

Not much of an update as far as major progress goes as today's jobs were time consuming. Lots of trimming, taking out and putting in the sill over and over and over again until it was fitting right.

As well as that,i was helping out elsewhere in the workshop which took me away from the mini unfortunately 

 

First of all, here is the photo of that crusty flitch i mentioned yesterday

 

 

So that went first. i kept as much of it as i could for now as i wont be replacing that bit until the sill is in and finished.

 

 

 

 

Then i trial fitted the sill for the first time....

...It didn't fit 

 

And here was the problem

 

 

It needed to go up. I know the heelboard end is in the right place so i just trimmed the inner sill to suit

 

 

And then the fit was better

 

 

 

 

Then i pulled it in and out probably another dozen times to trim and adjust until i was happy with the fit.

Then i spent close to 2 hours sorting out the seams on the door step as they had several layers of old sill seams rusted into one lump on them so took quite a bit of careful grinding to get them off cleanly. even then, I still had to chop out some sections to replace as they were too thin.

 

Once that was complete, i put the sill back in and clamped it all up tightly.

 

I used a scissor jack on the front of the floor to pull the two layers where the new and old are overlapping tightly together. I used a portapower on the back 

 

 

Once the two overlaps were pulled tightly together. i lifted the car and marked out the cut line from underneath

 

 

Then took the sill back off and cut the excess off of the existing floor in preparation for the butt weld join

 

 

 

An then liberal lashings of Zinc primer

 

 

 

and inside the crossmember too. We have a new zinc primer which sprays at a really high pressure so it goes in everywhere which is great. It sticks really well too as i can't fr the life of me shift it from my skin

 

I did get it clamped back up again but ran out of time. 

 

Tomorrow, it will be welded in and done.

 

Then onto the other side...

 

Ben

[James_eaton_thewholething]

Were do you get the zinc from ?

[markyB]

What is this fancy new zinc primer you speak of ??
Top work as always Ben ,I love your methodical approach

[FAZ]

whats the bracket beneath the rear seat bench? next to the tunnel

[jamesquintin]

whats the bracket beneath the rear seat bench? next to the tunnel

 

its for the airbag control box thing

Edited by jamesquintin, 11 December 2015 - 04:40 PM.

[Ben_O]

Were do you get the zinc from ?

From our paint supplier. i can't remember what it is called but i am sure the can will feature in one of the photos on to today's update.

 

What is this fancy new zinc primer you speak of ??
Top work as always Ben ,I love your methodical approach

Cheers! Ill try and find out what it is called

 

 

whats the bracket beneath the rear seat bench? next to the tunnel

 

its for the airbag control box thing

 

That's right. The module bolts to that bracket.

[Ben_O]

Most of the O/S sill is complete now. 

 

I started the day by finishing the prep on the sill assembly.

I did have it in and ready yesterday but released this morning that i had forgotten to punch holes for plug welding so i took it back out and sorted that.

 

Here it is all in, lined up, measured and measured again then checked and checked again.... You get the idea!

 

 

And then once happy,i tacked it in 

 

 

 

Once it was held in securely and the clamps could come out, i tried the door which shuts ok and lines up nicely. It's always best to check that at this stage so that you know that nothing has moved and that the step is in line nicely with the bottom of the door.

 

 

Everything is looking nice and tight in the companion bin too

 

 

Once the floor join was fully seam welded, i began the grinding down. I won't finish the final grinding until prep time when i can get in the properly with the brace out of the way.

 

Here is the front join

 

 

I need to also blank off one of those drain holes too.

 

I ended up removing the tacks that was holding the new crossmember end in as i wasn't happy with the way it sat with the inner sill. I could have persuaded the edges in closer with a hammer and bolster but decided not too.

Once they were removed, i moved it closer to the inner sill (about 4mm) I double checked the distance between the seal lips on the steps too at this point just to make sure and it was bang on 50" which is correct.

 

Got the rest of the welding finished too

 

 

 

 

There are some more repairs needed to the step seams in places so that will just be a case of cutting out the thin bits and letting in new steel

 

 

I also made this up

 

 

which goes here

 

 

It will be seam welded to the companion bin to replace the tang that was there originally. There wasn't one when i started on it as it had been cut off and the bin seam welded to the floor 

other than that, it will be plug welded to the inner sill.

 

There are just a few finishing touches to do Monday morning then i will get straight on to the other side. The flitch repair will be done when both sills are finished as i need the lift jack to raise the front to get the wheel off. It's currently holding the back of the car up...

 

Hopefully going to paint it mid week if all goes well!

 

A sneak peek at the next project..

 

 

 

Ben

[sonikk4]

Every one of the inner sills i have had to notch at the back to get them to fit correctly. i also had trouble on all of them at the footwell as well. Other than that they fitted well. 

[Ben_O]

Every one of the inner sills i have had to notch at the back to get them to fit correctly. i also had trouble on all of them at the footwell as well. Other than that they fitted well. 

This one wasn't too bad at the front. I just tacked and worked forwards until i came to the front of the footwell depression and used a bolster to take the original floor part back slightly and then a hammer and dolly to bring them level.

 

I was expecting to have to slot it though.

Still, there is the other side to do yet so that may well need slotting

[Ben_O]

I missed out the photo of the rear join somehow...

 

 

 

Only partially ground up at this point

[spraybeater]

Top job on this! good to see someone whom takes a pride in their work,and takes the time to explain and

add photos for the the folks that are not experts,especially in these days of financial constraints on business .

The MMachine floor/sill panels help to keep outer look original! I  had to check out rear inner and modify front

also.

The photo off the next project brought back some memories!! used to have German woman customer back in

the seventies that did that to her V8 MGB GT on a regular basis, and always wanted it repaired without her

husband knowing   

[alchall]

I completely missed you starting this new topic, good to see your handy work again, shame it's not your own car but it's looking good as always!

[Ben_O]

Another day on the cooper today.

Plan of attack was to finish the O/S sill and try and get the N/S one cut out.

 

First of all, that repair piece for the companion bin needed to be welded in.

 

 

And then grind down

 

 

Then i prepped and clamped in the closing first panel.

 

 

Note the heavy coat of zinc in there 

 

Once welded in and cleaned back, the second closer was clamped in

 

 

And that completes the back end of the sill fitting

 

 

Next on to sorting this mess

 

 

The edge of the step is all thin and perforated  so i cut it out

 

 

And a new piece was made up

 

 

Trimmed and welded in

 

 

Much better

 

 

So bar the flitch repair, that side is now done

 

 

Onto the other side now

 

Ill do it in pictures as i have covered the process with the other side

 

 

 

 

 

 

 

 

 

 

Just the remaining edges to remove now and a bit of a trim here and there and the new one can go in.

 

This was the better side of the car so hopefully progress will be faster.

 

More tomorrow

 

Ben

[minimissions]

Nice work seriously tidy :) like it that will be one more solid late cooper soon on the road then :)

[domdee]

great build. looking forward to more